Feature Story

Next generation 'EPS foam' is biobased and recyclable as paper

The constant search for environmentally friendly packaging solutions has led to a groundbreaking development: a cellulose-based material that is a sustainable replacement for traditional expanded polystyrene (EPS) products. This biobased replacement for foam molded EPS is made from cellulose-based materials instead of fossil fuel and has significant environmental benefits on several levels. Among these is its ability to be recycled as paper.

August 2024

Today, the use of EPS foam is widespread. It is perhaps best known for protecting consumer products during transport, serving as disposable packaging for various purposes, acting as insulation components for the construction industry, and for molding custom solutions. EPS foam has been a popular material for various industries due to its low weight and good insulating properties. The negative environmental impact of traditional polystyrene foam is now being addressed from various perspectives, including the use of renewable raw materials in production to reduce greenhouse gas emissions and the recycling of polystyrene to prevent it from ending up in landfills or incinerators. The biodegradable alternatives now being developed offer even greater value by further improving environmental sustainability.

Sustainable perspectives on food packaging

The transition to sustainability

In response to the environmental challenges posed by traditional EPS foam, Nouryon, MoRe Research, a part of the Swedish research institute RISE, and EPS foam producer LindePac launched a government-funded project in 2019 to demonstrate that this type of biobased EPS foam can become a reality.

Nouryon contributed with its globally renowned product, Expancel® microspheres, in various forms. These expandable microspheres serve as a crucial additive in the granule production phase by acting as a formidable blowing agent and providing lightweight, shock-absorbent, and insulation properties to the material.

Years of research have led to the production of a cellulose-based granulate with equivalent properties to today's traditional EPS, allowing a drop-in alternative for foam molding. The new material has a biodegradability of over 95%, with the ambition to reach full biodegradability. With a composition of over 95% cellulose, it can easily be recycled together with other paper products.

Cellulose based sustainable replacement for traditional expanded polystyrene (EPS) products

Current results and future potential

Today, the project is run by a dozen experts from partners Nouryon, MoRe Research, LindePac, and the start-up Cellofibers Sweden AB. The team is working on further development, product testing, and commercialization strategies. A patent application has been filed for what is now called Cellofiber granules, and the material has already attracted attention for its environmental and practical benefits. Full-scale tests in molded EPS foam production facilities in Sweden as well as field evaluations of foamed products with end customers are planned for 2024 to fine-tune the performance of the granules. Nouryon and Cellofibers share ownership of the first patent application, indicating strong collaboration and a common vision for the success of the project.

sustainable replacement for traditional expanded polystyrene (EPS) products

Looking ahead

The technology will be developed by Cellofibers Sweden in close collaboration with Nouryon. Future milestones will include following up on the results of full-scale tests to further refine the product and initiating evaluations with potential customers to move closer to a market introduction.

 

Related content

Expancel Microspheres

Expancel® Microspheres is a lightweight filler and a blowing agent in one. Read more on how it can enhance and be used in a multitude of applications.
Woman receiving take away from a food truck. The high compressibility of Expancel microspheres ensures resilient seals for food packaging.

Food packaging

The high compressibility of Expancel microspheres ensures resilient seals for food packaging, without shrinkage or water absorption.

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